Ultrasonic spot welding of dissimilar 2024Al alloy and SiCp/2009Al composite

Dissimilar welding of 2024Al alloy to SiC/2009Al composite was conducted via solid-state ultrasonic spot welding technique. Defect-free sound spot welds were successfully achieved. SiCp particles were observed to migrate from the composite side to 2024Al side along with the interfacial interlocking during the intense high-frequency rubbing, which increased with increasing welding energy. The microhardness across the ultrasonic spot welded similar and dissimilar joints remained nearly constant. The tensile lap shear failure load increased with increasing welding energy, and satisfied the requirements of AWS standard D17.2 for spot welding. In addition to room temperature tensile lap shear tests, all the similar and dissimilar joints were subjected to tensile tests at varying temperatures and their respective results were discussed